Fighting Unplanned Downtime: GREIF-VELOX Increases Equipment Availability with Smart Technology

A recent study by Deutsche Messe Technology Academy and Moxa highlights one of the biggest challenges in industrial production: unplanned downtime. At GREIF-VELOX, we are driving sustainable improvements in Overall Equipment Effectiveness (OEE) through digital innovations and intelligent system design.

The joint study by Deutsche Messe Technology Academy and automation expert Moxa reveals a sobering reality in German industry: 94% of surveyed companies experience at least one unplanned production stop per month, with an average duration of 3.3 hours. The consequences are severe – just one hour of downtime can cost millions, especially in highly automated processes. The economic fallout ranges from missed delivery deadlines and increased personnel requirements to reputational damage.

The study identifies key causes for unexpected production stops:

• Failure of machine components or IT systems
• Lack of transparency on equipment condition
• Delays or difficulties in spare parts procurement

The result: Inefficiencies, reactive maintenance, growing pressure on technical teams – and ultimately, a drop in Overall Equipment Effectiveness (OEE).

At GREIF-VELOX, we develop solutions that directly target these challenges. By combining intelligent sensor technology, real-time data analysis, and practical support tools, we help customers significantly reduce downtime and secure long-term process reliability.

Our condition monitoring solution, VeloGuard, plays a central role in preventing unexpected breakdowns. It automatically detects typical wear patterns and continuously monitors the health of critical components through self-diagnostic tests. This eliminates the need for time-consuming troubleshooting and allows teams to address potential faults early and with precision – resulting in improved production reliability, predictable maintenance cycles, and drastically reduced downtimes.

While VeloGuard acts as a preventative measure, VeloInside provides operational transparency. This digital real-time dashboard offers all key performance indicators at a glance. Availability, performance, and quality metrics are visualized within an integrated OEE dashboard, making weak points visible and enabling data-driven improvements. It’s a decisive step toward proactive maintenance management.

One often underestimated contributor to long downtimes is the difficulty in sourcing the right spare part. That’s why we developed VeloXparts: a digital spare parts system that uses machine-specific QR codes directly on the equipment. This allows users to instantly access the correct parts overview, eliminating misunderstandings, incorrect orders, and time-consuming back-and-forth. The result: minimized downtime, reduced ordering errors, and significant relief for technical teams – all with no extra training required.

A concrete example of our component innovation is the newly developed UltraRubberBellow. In applications involving abrasive materials such as silica, traditional seals are often a weak point. The new bellow, used with our updated filling spout, increases the service life from the usual 2,000–10,000 cycles to up to 125,000 cycles. This significantly reduces maintenance, cleaning costs, and material usage. The integrated EasyBell quick-change system allows for rapid replacement – further reducing unplanned downtimes.

Despite all preventive efforts, unforeseen failures can still occur. Our multi-level support system ensures you’re never left alone: with VeloXpert Remote Support, up to 95% of issues can be resolved within 24 hours – without the need for an on-site visit. For more complex cases, our global service technicians are on-site within one to five days.

From predictive maintenance and digital analytics to wear-optimized components and dependable support – GREIF-VELOX delivers integrated solutions that bring our customers significantly closer to uninterrupted production.

You want to sustainably increase your equipment availability?

Get in touch with us: We are happy to advise you based on your specific needs.

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